Process and means for producing artificial flower leaves



April 19, 1949. H. B. OWENS ETAL 2,467,565

PROCESS AND MEANS FOR PRODUCING ARTIFICIAL FLOWER LEAVES Filed June 27, 1945 4 Sheets-Sheet 1 :ZZE

INVEN T015.

HENE? B OWENS.

JOHN H. DERRICK.

Apnl l9, H, B. OWENS ETAL PROCESS AND MEANS FOR PRODUCING ARTIFICIAL FLOWER LEAVES Filed June 2'7, 1945 4 Sheets-Sheet 2 INVENTORS. HENRY B. OWENS.

JOHN H. DERRICK.

April 19, 1949. H. B. OWENS ET AL 2,467,565

PROCESS AND MEANS FOR PRODUCING 4 ARTIFICIAL FLOWER LEAVES Filed June 27, 1945 4 Sheets-Sheet 3 Z4 J I .61

/Z4a [46 [46 I.

276 7c 2 pg I I 145 U INVENTORS. HEN/2v B. OWENS.

JOHN H. DEER/CK.

I 136 1: I NIH/1h HUM I mllm HHHHHHH.

' Apnl 19, 1949. H. B. OWENS ET AL 2,467,565

PROCESS AND MEANS FOR PRODUCING ARTIFICIAL FLOWER LEAVES Filed June 27, 1945 4 Sheets-Sheet 4 l I I I129 JOHN H. DEER/CK 29 BY Patented Apr. 19, 1949 PROCESS AND MEANS FOR PRODUCING ARTIFICIAL FLOWER LEAVES Henry B. Owens and John H. Derrick, New York, N. Y., assignors to The Leaf Manufacturing Corporation, New York, N. Y.

Application June 27, 1945, Serial No. 601,762

11 Claims.

This invention generally relates to process and means for producing laminated articles made from substantially non-rigid material and refers more particularly to process and means for manufacturing laminated leaves or similar articles used in the artificial flower or related industries, said articles being preferably traversed by a wire or similar element which forms the stem and also a stiffening means for the article.

It is one of the main objects of this invention to automatically and continuously produce artifioial flower leaf or leaves.

It is another object of the invention to provide means for fabricating from an endless roll or rolls of non-rigid material flat laminated articles, such as leaves, each having between the laminae an element imparting a predetermined stillness to the article or articles and extending with one end within and short of the boundary of the article.

It is a further object of this invention to provide an uninterrupted process for producing articles of the kind described from band or tape means moved from one station for feeding or unwinding said tape means to another station at which said tape means is again wound up or collected.

Yet, another object of this invention is to provide means for producing a plurality of laminated articles in succession from tape means, the latter being moved in timed relation to positively guided severing means.

Still a further object of this invention is to provide a process for joining or welding together a plurality of tape means fed from endless rolls and to expose in the course of said process said tape means to the influence of heat and pressure.

Still another object of this invention is to provide means affording the connection of a thermoplastic or like backing with a top layer of non-rigid material in superposed relation and with pliable stiffening means positioned therebetween to thereby obtain formable article or articles.

A still further object of this invention is to provide process and means for inexpensively manufacturinng artificial flower leaves of varying sizes and shapes, the steps of said process being simple and easily to coordin-ateto each other so as to insure speedy mass production of said articles.

These and other objects and advantages will become more apparent from the ensuing description of the invention, and will be further clearly 2 understood by referring to the accompanying, drawings.

In the drawings:

Fig. l is a side-elevational view of the machine for producing artificial leaves;

Fig. 2 is a top plan view of the machine shown in Fig. 1; I

Fig. 3 is an enlarged plan view of the wire cutting and leaf die mechanism;

Fig. 4 is an enlarged diagrammatic detail view of the wire cutting mechanism taken along line 4-4 of Fig. 3;

Fig. 5 is an exploded view of the three component parts of each leaf;

Fig. 6 is a plan view (partly broken away) of a completed leaf;

Fig. 7 is a diagrammatic plan view of the tapes of which the leaf is formed and illustratin pro-- gressive steps of the formation of the leaf;

Fig, 8 is an enlarged diagrammatic sectional view of the tape notch-cutting mechanism taken along line 88 of Fig. 3;

Fig. 9 is an enlarged, side-elevational view of the leaf forming die and its mechanism;

Fig. 10 is a sectional View of the mechanism of Fig. 9 taken along line I0--l 0 of Fig. 9.

Fig. 11 is a diagrammatic view of the operative parts or means working on the tapes and shown in their respective relation to each other;

Fig. 12 is a respective detai1 view of the wire feed mechanism, taken along line l2-l 2 of Fig. 3.

Referring now in greater detail to the attached drawings, there is disclosed for the pur-,

pose of arriving at the present invention a substantially fiat article, such as an artificial flowerleaf 20. This article comprises a top layer 2| made of a non-rigid, preferably fabric or like appropriate material which may be suitably dyed and embossed as at Ma; a backing or base layer 22 made of paper or other cellulosic material provided on one of its faces with a prefarablythermoplastic substance 23; and a metal wire or like stem-forming element 24 of relatively stiff, but pliable material juxtaposed with re-' spect to said top layer 2| (Figs. 5 and 6). This element 24 extends from one end or edge of the leaf 20 toward an opposite edge of said leaf- (Fig. 6) to terminate a predetermined distance and short of said opposite edge so that one end of said element 24 is located short of and within:

timate position. To this end, tape 26, as seen in Fig. 7, is covered with any known thermoplastic material or another suitable binding mass 23 which may harden under the influence of applied heat and pressure. As shown in Fig. '7, lower tape or band 26 is provided with a series of spaced notches 21, 21a, 21b, 210, etc. for apurpose later described.

Between said welded or joined tapes 25, 26, there are interpositioned in spaced relation to each other stem-forming elements, such as pieces of wire 24a, 24b, 240, each of predetermined length as will be easily realized.

By successive cutting or stamping operations out of thus prepared tapes 25, 26 by means of suitably shaped die mechanisms or severing means, hereinafter more fully described, leaflike laminated articles, such as illustrated in Fig. 6, are obtained.

Each of these laminated articles consists of atilea'st two layers 2|, 22 withinterposed wire element 24. The remnant or waste portion 28 of tapes 25, 26 in their welded condition and after the respective leaves have been stamped out and removed, thus leaving spaces or openlugs 30 in said tape waste portion 28, is wound up on conventional reel means, such as indicated at station 29 (Fig. 11).

In order to more clearly explain the steps of producing the article herein described, it will be realized'that mechanisms and means for continuously manufacturing said article mainly consistof the following parts:

The rack 50 with take-oil reels, the guide rollers the intermittently operated set of feeding or pulling rollers 52, the driving and regulating mechanism 53, the wire supply and notch mechanism 54, the stamp or die 55 with cam drive 56 and the take-up reel 29.

Rack50 consists of the bracket 60 having an inclined slot 6| forming a bearing'for the axle of lower reel 62 and the slot 63'acting as a bearingfor the axle of upper reel 64. Brackets 60 and other parts hereinafter described are affixed to a table or frame 65.

Guide rollers 66 and 61 are mounted for rotation'within the bracket 68, top roller 66 being adjustable with respect to roller 61 at 66:; and acting as a pressure roller. The tapes 25, 26'hereinabovereferred to running from reels 62, 64 to reelstation 29 (Fig. 11) pass between said guide rollers 66, 61 unto the bracket 69 carrying the tape pulling or feed rollers andTI. Rollers 16, II are preferably provided with knurled surfaces 12 for enhancing the gripping action on and forward movement of the tapes and 26.

The roller II is geared to the intermittent driving mechanism 53 which causesadvancing movement of tapes '25 and 26 from one die operation position to the adjacent one. This movement occurs intermittently and is brought about by means of a motor M with reduction gearing including a gear 13 in mesh witha larger gear ll. Gear 14 is mounted on shaft'15 which also carries a crank arm I6 provided with slot" for adjustment purposes and for varying the effective length of arm "I6, as it is well understood. An adjustable lever I8is attached at its one'end to crank arm 16 and at its other end to the ratchet arm 19 which in turn is 'fulcrumed on shaft 86, the latter also carrying-the'feedroller H. Arm [9 is mountedon'shaft 86 to swing freely and idly onthe latter; About at the middle o'f-Jarm'lil, there is located'a driving pawl 81 and spring 82 *which keepsfsaid pawl in contact with 4 a ratchet wheel 83 suitably keyed to shaft 83a which is supported by frame 65 (not shown). Ratchet wheel 83 is in turn secured to a gear 84 which is also affixed to shaft 83a and is in mesh with a pinion 85 mounted on shaft 86.

It does not afford any difficulty to realize from the above, that the reciprocating movement (according to arrow A) of the adjusted lever 18 will cause the ratchet 8| to intermittently ad- Vance on ratchet wheel 83, thus causing gears B l, 85 to intermittently drive pulling roller 'I'I'.

Tapes 25, 26 now pass, respectively, over and under the separator member 86 supported on bracket 85a from Where the two tapes 25, 26 are guided between tracks or guide pieces 8?, 88 (Figs. 2 and 3). Guide pieces 81, 88 are secured to the table 65 by means of bolts 89. As it may be desired to change the width of the tapes 25, 26 according to the size and shape of the article to be manufactured, threaded holes or openings 88 for engagement with said bolts 89 are provided in the surface of the table 65 for the aforesaid purpose.

Shaft 15 is geared by means of bevel gears SI to an upright shaft 92, which is supported in several spacedly arranged bearing blocks 93. The set of bevel gears 94 connects shaft 92 with a pair of bevel gears 95, which drive the shafts 96 and 97. Shaft 96 is arranged to drive a shaft 98 by means of a chain 59 and sprocket wheels I00.

Shafts 96 and 98 are mounted within the bearing block IBI. Secured to shaft 98 is a wire pulling roller I82 having the groove I 03 and in contact therewith the roller I64 with the complementary groove I05. This roller I84 is pressed against roller I02 by means of a pressure spring IDS.

Wire i0? is fed from reel I28 which is supported by table '35 at mm, the wire running between rollers I82 and I84 into the cutting device I 09 provided with the cutting edge IIU (Fig. 4). The cutting arm III is fulcrurned at H2 and-secured at H3 to an eccentric H4 which in turn is driven by gears H6, I I5 from the shaft 91 andbevel gears (Fig. 3). Gear H5 is mounted on and fixed to shaft II! which carries adjacent its end an eccentric II 8 (similar to that designated-by numeral H4), which in turn connects by means of the arm H9 to a notch cutter I20 whichis fulcrumed at I2lla (Fig. 8). The guide piece 88 for thL purpose is provided with a cut out at I2I, permitting cutter I20 to cut through backing tape 26 notches 21, 21a, 21b, 210, etc. only at predetermined intervals and in timed relation to the relative movements of the wire Ill'l (transverse movement) and tapes 25, 26 (longitudinal movement).

The wire I61, as above mentioned, is cut at I I 0 after the wire has been fed through rollers ID5I83 along guide IIZIa which is provided with a longitudinal lateral discharge slot Heb of appropriate shape. The thus cut wire 24 of predetermined length has been previously inserted between tapes 25 and '26 as it is apparent from Fig. 3 and shown in detail in Figs. 5 and 6. To prevent any shifting of the wire 24 after having been cut to desired length, it is desired to immediately compress at least portions of the tapes 25 and 28 together for which reason guide piece 8? may carry on extension bracket 81a the soft rubber roller I22 journaled on shaft I22a. Roller I22 may be made to slide lengthwise of guide fl'lfor adjusting purposes. Instead of pressure roller I22 any other suitable meansmay be applied to maintain inserted Wirepiece'24 at'its location of insertion. Guide piece 81 further carries an electrically heated table portion I23 at I23a which will permit the thermoplastic matenial 23 of tape 25 to soften sufficiently so as to cause tapes 25, 26 to adhere to each other, thus holding fed wire piece 24 securely in place while passing under resilient roller I22.

Tap-es 25, 25 with properly spaced wire lengths 24 are now ready to enter between female die I24 and male die I25 (Figs. 1, 9 and Driven from shaft 92 by means of bevel gears I26 is an eccentric wheel I21 mounted on shaft I28. The rotation of the cam or eccentric wheel I21 causes plunger I29 to which the die member I24 is secured, to descend upon the male member I whereby articles of desired shape and form, such as artificial flower leaves, may be cut out in mass production. To prevent the adhering tape portions from which the cut out has been made from sticking to the male die member I25, it is desirable to provide pusher or ejector means I which is held captive and guided on pins IBI carrying coil springs I32 so as to ensure that ejector plate I 35 will always be retracted to its uppermost position.

The male die I25 is preferably provided with a heating element I33. Plunger I29 is carried within hollow bearing I34 affixed to said plunger by a transverse pin I35.

A coil spring I36 in pressing against the said pin I35 and against the closure plate I3? will keep plunger I29 in its uppermost position and in engagement with the surface I38 of cam I2I. Hollow bearing IE4 is provided with arms or ribs I39 to connect the bearing I34 with the standards or uprights I40 which in turn are secured to the table (Figs. 2, 9 and 10).

It is well understood that the die members I24 and I25 are designed to be easily replaced and exchanged according to shape and size of the material to be stamped out.

It is also apparent from the drawings that the female die member I24 is provided with a slot I4I, which provides clearance for wire 24 protruding from one end of the joined tapes 25, 26 during the punching or severing operation. As can be readily seen from Fig. 7, it is essential to provide the notch 21 extending transversely to one of said tapes and from one side edge thereof up to the end I42 of the article to be stamped out, thus permitting wire 24 and the leaf 28 to be readily removed from joined tapes 25, 26, at the same time however, providing for material I43 and I ld to be left at both ends of the cut out article so as to facilitate and permit the collecting or winding up of the remnant or waste tape 28 (Fig. 11) at reel station 29.

The operation of the machine is as follows:

Two reels of material 52 and 54 are placed in the bracket 65. The reel 64 carries a tape roll of a suitable, water-repellent and dyed material used for the top surface of an artificial leaf or like article, while the lower reel 52 carries a roll of a tape of material having that side facing the top tape 25 covered with a thermoplastic or other cementing mass. The two tapes 25, 26 are now threaded between the guide roller 56 and I51 and pulled through the intermittently working feeding rollers I5, II, thence over and under the separator member 85 to the guide means, notch mechanism and wire supply at 54, and finally between the female and male die members I24, I25 unto the waste wind-up reel at 29.

By starting motor M, the same will drive by means of pinion I3 and gear 14 the shaft 15.

The movements of lever 19 in the direction 0 arrow B cause feeding or pulling roller II to be rotated clockwise, whereas the same remains stationary when lever 19 is moved in the direction of arrow C. During the time period When feeding roller II remains stationary tapes 25, 26 will be prevented from forward movement, thus will be held stationary in the machine, during which time the following steps of the process and function of the following parts take place:

Wire It! is cut into the desired piece length 24 by the cutting mechanism IIl9-I III, notch 21 is cut into tape 26 by means of cutter I20 and female die I24 descends upon male die I25, thus causing the previously prepared article and now advanced in timed relation to the die mechanism 55-56, so as to be cut out of the welded tapes 25, 26 with a wire length 24 therebetween.

In accordance with the design of the machine, it may take several intermittent motions before the prepared tapes 25, 26 with newly cut notch 27 and the inserted wire length 24 reach the die members I24, I25. K

The cut out article, such as leaf 20, can be readily removed by hand from between the cutting dies I24, I25.

Any conventional means, such as jets of compressed air; automatically released sweeping-devices, such as rotary brushes; or suction devices of any known construction (not shown) may be employed for such purpose.

It is well understood that the thickness and quality of the material of the tapes may vary ac-'- cording to the articles to be produced and that the coating herein referred to may be thermoplastic (containing nitrocellulose with resins and plasticizer), or of pressure-sensitive adhesive character. The process may also be carried out with a dry-gluing mass, lacquer or veneer having binding properties, plastics and plastic compositions suitable for the purpose of effectuating adhesion and firm connection of the laminae of which the resultant article consists. The wire element herein described may be covered with cotton, paper, etc., if desired, and may have any shape or configuration (fiat, oval, etc.).

The machine may be equipped with conventional controlling and motion interrupting devices to automatically stop the machine, if any obstruction, tearing of the tape material, etc.,. should occur.

According to the present invention, there has been provided a process and means for producing laminated articles, such as artificial flower or plant leaves with stems, which consists in joining together a plurality of endless tapes made of non-rigid material, at least one of said tapes being provided with a mass susceptible of joining said tapes together, introducing between adjacent tapes a stem-forming element made of a material relatively more rigid than said tape materials and extending short of that edge of said tapes positioned opposite the edge from which said element is introduced, subjecting said joined tapes with said introduced element to a stamping operation to thereby provide a cut-out article, removing said article from the remainder of said joined tapes, and finally winding up the remainder of said joined tapes.

While there have been shown and described and'mointed rout the fundamental novel features of thelinventioniaszapplied to the :above embodiment, it .willbe understood that various omissions and substitutions and changes in theform and details of the device and methods above described and illustrated may be made by those skilled in the art without departing from the spiritcof the invention.

.Having thus described the invention, what is claimed as new and desired to be secured by Letters Patent, .is:

l. The methodofzcontinuously producing lammated articles in the form of leaves with stems, which consists in feeding elongated tapes of equal lengthlandlin superposed position in substantially lengthwise direction of said tapes, maintainingsaid tapes in spaced apart :relation toweach other while beingfed, then inserting transversely to said tapes therebetween pieces of-stem-forming material in spaced apart relation-to each other, whereby the latter project from one ofthe edges of said tapes therebeyond toward'the opposite edges of said tapes but short of the latter edges, thereafter bonding said superposed-tapes together so as to obtain a continuous and bonded tape reinforced withsaid stemeforming pieces encased therein, subjecting said continuous bonded tape to die-cutting operationlin which that part of said bonded tape containing .a. respective piece of stem-forming material and positioned intermediate said edges isiremoved fromsaid bonded tape, and finally collecting the remainder of said tape with at least :one lOf said :edges substantially intact.

'2. '-The'method of continuously producing laminated articles in the form-of leaves with stems, which consists infeeding elongated tapes of equal lengthand in superposed position in substantially lengthwise direction of said tapes, maintaining saidtapes in spaced apartrelation to each other while'being fed, then inserting transversely to said tapes therebetween pieces of stem-forming material in spaced apart relation to each other, whereby the latterproject from juxtaposed edges ofsaidtapes therebeyond toward opposite edges ofsaid tapes but short of the latter edges, thereafter'bonding said superposed tapes together so as to obtain-a continuous and bonded tape reinforced with -said stem-forming pieces encased therein, subjecting said continuous bonded tape to die-cutting operation in which that part of saidbonded tape containing a respective piece of stem-forming material and positioned intermediate said edges is removed from said bonded tape, and finally reelingup'theremainder of said tape with at least one of said edges substantially intact.

'3. The method of continuously producing laminated leaf articles-with stems, which consists-in feeding 'aplurality oftapes of non-rigid material, coating'one of said tapes onthe surface thereof witha bonding material, superposing said tapes in spaced apart-relation so thatsaid coated surface of:said one tape faces the surface of said other tape, advancing saidtapes simultaneously and intermittently in the directionof feed of said tapes, cutting notches in at least one edge of said tapes, feeding;pieces of stem material, and inserting successively said; pieces of-stem material intransverse direction to said tapes and therebetween at locations thereof where notches have been cut so that said pieces of stem -material project with one end thereof from between the edges'at one side of said tapes toward the edges on .the opposite sideofsaid'tapes but short-of the latter, bonding said tapes to said 'pieces of stem material so as to prevent displacement thereof relative to said tapes, thensevering said leaf articles frolmsaid bonded tapesat the 'locations of said pieces of stem material, andflnally collecting the remainder of said tapes.

4. The method of continuously producing laminated leaf articles with stems, which consists in feeding a plurality of tapes of non-rigid material, coating one of said tapes on the surface thereof with a bonding material, superposing said tapes in spaced apart relation so that said coated surface of said one tape faces the surface of said other tape, advancing said tapes simultaneously and intermittently in the direction of feed of said tapeacutting notches in at least one edge of said tapes, feeding pieces of stem material, and inserting successively said pieces of stem material in transverse direction to. said tapesand therebetweenat locations thereof where notches have been cut so that said pieces of stemmaterial project with one end thereoffrom between the edges at one side of said tapes-toward the edges on the opposite side of said tapes but short of the latter, bonding said tapes to said pieces of stem material so as to prevent displacement thereof relative to said tapes, then severing said leaf articles from said'bonded tapes at the locations of said pieces of stem material, and finally reeling up the remainder of said tapes with'at least'one of said edges substantially intact.

5. A machine for continuously producing laminated leaves with stems comprising a machine frame, an elongated support on said machine frame, feeding means on one end of said machine frame for supplying two superimposed tapes along said support, spacing means on said support for maintaining said tapes separated along a part of said support, a mechanism on said machine frame forfeeding stem-forming material, means for cutting predetermined lengths of stems from said stem-forming material 1 and for inserting said stems between said separated tapes to assume a position with respect to saidtapes so that each of said-stems projects in a directionfrom between the edgeson one side of saidtapes to terminate short of the opposite edges on the other side of said tapes, a compression element on said machine frame and opposite said mechanis'rnfor exerting pressure upon said tapes and a respective stem inserted therebetween so as to prevent displacement of said stem relative to said tapes, stamping means onsaid machine frame extending above said support and adapted'to 'compressively join said tapes to each other and to said stem therebetween, said stamping meansincluding die cutting means for simultaneously severing a plurality of leaf shapesout of the-intermediate portion of said tapes when joined together so as toZleave-the edges of said tapes intact, reel means on the opposite end of said machine frame to gather theremainder of said tapes after passage thereof through said stamping means, and driving means ,on said machine frame operatively connected to said feeding means, said mechanism, said stamping means and said die-cutting means for actuating all said means and said mechanism in timed relation, said tapes extending uninterruptedly from said feeding means-to said reel means.

6. A machine according to claim 5, wherein said spacing means consists of a bar extending transversely across said support and arranged to separate said tapes in amannerthatone of saidtapes passes over said bar,-while the 'other of said tapes passes below said bar.

7. A machine for continuously producing laminated leaves with stems comprising a machine frame, an elongated support on said machine frame, feeding means on said machine frame for supplying two superimposed tapes along said support, spacing means on said support for maintaining said tapes separated along a part of said support, notching means on said machine frame for intermittently forming notches in at least one or said tapes, a mechanism on said machine frame for feeding stem-forming material, means for cutting predetermined lengths of stems from said stem-forming material and for inserting said stems between said separated tapes at locations thereof coinciding with said notches to assume a position with respect to said tapes so that each of said stems projects in a direction from between said edges on one side of said tapes to terminate short of the opposite edges on the other side of said tapes, a compression element on said machine frame exerting pressure upon said tapes and a respective stem inserted therebetweenso as to prevent displacement of said stem relative to said tapes, stamping means on said machine frame extending over said support and adapted to compressively join said tapes to each other and to said stem therebetween, said stamping means including die cutting means for simultaneously severing a plurality of leaf shapes out of intermediate portions of said tapes so as to leave said edges of said tapes intact, real means on said machine frame at the end of said support to gather the remainder of said tapes after passage thereof through said stamping means, and driving means on said machine frame operatively connected to said feeding means, said notch means, said mechanism, said stamping means and said die cutting means for actuating said means and said mechanism in timed relation, said tapes extending from said feeding means to said reel means.

8. In a machine according to claim 7, wherein said notching means is positioned adjacent one of the edges of one of said tapes.

9. In a machine according to claim 7, wherein said mechanism includes stem feeding means for inserting predetermined lengths of stem forming material transversely between said tapes at said locations of said notches.

10. In a machine according to claim '7, wherein said notching means are positioned substantially in alignment with said mechanism, and respective guide means positioned on opposite sides of said tapes for guiding the latter, one of said guide means being positioned in proximity of said mechanism, the other of said guide means being positioned adjacent said compression element.

11. In a machine according to claim 10, wherein both said guide means are adjustably disposed with respect to said support.

HENRY B. OWENS. JOHN H. DERRICK.

REFERENCES CITED The following references are of record in the file of this patent:

UNITED STATES PATENTS Number Name Date 1,394,037 Mallory Oct. 18, 1921 1,942,174 Kaplan Jan. 2, 1934 2,285,447 Lichter June 9, 1942 2,306,835 Tucker Dec. 29, 1942 

